Nonlinear detection circuit based on welding thermal change

Abstract

A nonlinear detection circuit based on welding thermal variation comprises a GPRS module and a single-chip microcomputer module and further comprises a voltage detection circuit, a current detection circuit, a light intensity detection circuit, a sound detection circuit and a distance detection circuit. The GPRS module, the single-chip microcomputer module, the voltage detection circuit, the current detection circuit, the light intensity detection circuit, the sound detection circuit and the spacing detection circuit are installed in the element box and electrically connected, the spacing detection circuit is matched with a distance measurement module, and the distance measurement module is installed at the upper end of a front arm of the machine. Based on the existing mature internet-of-things data receiving, transmitting and displaying technology, current, voltage, light intensity, sound and distance data between a welding gun head and a workpiece generated in the welding process can be collected and transmitted in real time, the working condition of the automatic welding robot can be known for related managers through PC or mobile phone application and based on the received various data in real time, and the working efficiency of the automatic welding robot can be improved. And when abnormity occurs, maintenance can be carried out on the site at the first time, technical support is achieved, and normal welding work of the automatic welding robot is guaranteed as much as possible.

Description

Technical Field

[0001] The utility model relates to the technical field of welding monitoring circuits, in particular to a non-linear detection circuit based on welding thermal deformation. Background Art

[0002] With the progress of industrial technology, various welding robots based on PLC or host computer programming control have been widely used. Specifically, under the control of the control software, the welding torch head at the front end of the mechanical forearm of the automatic welding robot performs welding operations at different angles and spacing positions of the workpiece.

[0003] Although the automatic welding robot realizes automatic welding operations to a certain extent, due to the unmanned working state, relevant management personnel cannot understand the specific welding process without on-site observation. When problems occur during welding due to various reasons and cannot be disposed of in time, it will have an adverse impact on the workpiece welding work. In fact, the current, voltage, light intensity, sound signal generated during welding, and the distance between the welding torch head and the welding part of the workpiece can all reflect the specific situation of workpiece welding from the side. For example, too large or too small current during welding may cause melting and deformation of the welding part of the workpiece and ineffective welding together; too large voltage may cause overheating and melting deformation of the relevant control circuit of the welding robot and the welding part of the workpiece, and too small voltage may also cause ineffective welding of the welding part of the workpiece. When there is no arc light or the arc light is too large during welding, when there is no sound signal or the sound signal is abnormal (too large or too small) during welding, it means that there is an abnormality in the workpiece welding work, and correspondingly, the welding work of the workpiece cannot proceed smoothly; when the distance between the front end of the welding torch head and the welding part is too far, the welding quality will be affected, and on the contrary, when the distance is too close, it may cause collisions between the front side of the welding torch head and the workpiece, etc., resulting in damage. With the progress of technology, the on-site relevant sensors collect analog voltage signals (such as the water pressure data voltage signal detected by the water pressure sensor and the pressure data of the oil cylinder acting on the workpiece output by the pressure sensor), then perform AD conversion through the single-chip microcomputer and transmit it remotely through the GPRS module. The remote relevant Internet devices (such as smart phones or PC machines) receive and display the data on the screen. The Internet of Things data transceiver and display technology has been applied to a certain extent. The remote relevant management can understand the relevant data in real time without going to the site, which provides effective technical support for relevant management work and understanding the working conditions of on-site working equipment based on data. To sum up, it is very necessary to provide a detection circuit that can collect, transmit and display the current, voltage, light intensity, sound signal generated during the welding process of the automatic welding robot, and the distance signal between the welding torch head and the welding part of the workpiece based on the existing mature Internet of Things data transceiver and display technology, so as to help relevant management personnel judge the working conditions of the automatic welding robot. Summary of the Utility Model

[0004] In order to overcome the lack of a practical data acquisition and transmission circuit in automatic welding robots, the present utility model provides a welding thermal deformation non-linear detection circuit based on the existing mature Internet of Things data transceiver and display technology. Under the joint action of relevant mechanisms, it can collect and transmit in real time the current, voltage, light intensity, sound, and the distance data between the welding torch head and the workpiece during the welding process. It provides technical support for relevant management parties to remotely understand the working conditions of automatic welding robots based on various received data through a PC or a smartphone application, and to rush to the scene for maintenance in the first time when abnormalities occur, thus ensuring the normal welding work of automatic welding robots as much as possible.

[0005] The technical solution adopted by the present utility model to solve its technical problems is as follows:

[0006] A welding thermal deformation non-linear detection circuit includes a GPRS module and a single-chip microcomputer module. It is characterized in that it also has a voltage detection circuit, a current detection circuit, a light intensity detection circuit, a sound detection circuit, and a distance detection circuit; the GPRS module, the single-chip microcomputer module, the voltage detection circuit, the current detection circuit, the light intensity detection circuit, the sound detection circuit, and the distance detection circuit are installed in an element box, and the element box is installed in the electric control box of the automatic welding robot. The distance detection circuit is equipped with a ranging module, and the ranging module is installed at the upper end of the machine forearm of the automatic welding robot and its detection head is aligned with the welding torch head of the machine forearm; the signal input end of the GPRS module is electrically connected to the signal output end of the single-chip microcomputer module, and the signal output ends of the voltage detection circuit, the current detection circuit, the light intensity detection circuit, the sound detection circuit, and the distance detection circuit are respectively electrically connected to the multiple signal inputs of the single-chip microcomputer module.

[0007] Further, the voltage detection circuit includes a rectifier bridge stack, resistors, and capacitors that are electrically connected. The positive power output end of the rectifier bridge stack is connected to the positive electrode of the capacitor and one end of the first resistor. The other end of the first resistor is connected to one end of the second resistor. The other end of the second resistor is connected to the negative electrode of the capacitor and the negative power output end of the rectifier bridge stack.

[0008] Further, the current detection circuit includes a resistor, a capacitor, a current transformer, and a rectifier bridge stack that are electrically connected. The secondary side power output end of the current transformer is respectively connected to both ends of the power input of the rectifier bridge stack. The positive power output end of the rectifier bridge stack is connected to the positive electrode of the capacitor and one end of the first resistor. The other end of the first resistor is connected to one end of the second resistor. The other end of the second resistor is connected to the negative electrode of the capacitor and the negative power output end of the rectifier bridge stack. The phase wire of the total power input end of the automatic welding robot passes through the central hole of the current transformer.

[0009] Further, the light intensity detection circuit includes a photosensitive resistor and a resistor connected electrically. One end of the photosensitive resistor is connected to one end of the resistor, and the light-receiving surface of the photosensitive resistor is located outside the front end of the component box.

[0010] Further, the sound detection circuit includes a voice control module and a resistor connected electrically. The power output terminal of the voice control module is connected to one end of the first resistor. The other end of the first resistor is connected to one end of the second resistor. The other end of the second resistor is connected to the negative power input terminal of the voice control module.

[0011] Further, the spacing detection circuit includes two resistors and is connected electrically to a ranging module. The signal output terminal of the ranging module is connected to one end of the first resistor. The other end of the first resistor is connected to one end of the second resistor. The other end of the second resistor is connected to the negative power input terminal of the ranging module.

[0012] Compared with the prior art, the beneficial effects of the present utility model are as follows: Based on the existing mature Internet of Things data transceiver and display technology, under the combined action of the voltage detection circuit, current detection circuit, light intensity detection circuit, sound detection circuit, spacing detection circuit, as well as the single-chip microcomputer module and the GPRS module, the present utility model can collect and transmit in real time the current, voltage, light intensity, sound, and the spacing data between the welding torch head and the workpiece generated during the welding process. For relevant management parties, remotely (such as a control room far from the welding area), via a PC or a smartphone application, based on the multiple data received in real time, they can understand the working conditions of the automatic welding robot. When an abnormality occurs, it provides technical support for them to rush to the scene for maintenance in the first time, and as much as possible ensures the normal welding work of the automatic welding robot. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present utility model will be further described below in conjunction with the drawings and embodiments.

[0014] Figure 1 is a schematic structural diagram of the present utility model.

[0015] Figure 2 is a circuit diagram of the present utility model. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0016] Figure 1 、 2As shown in the figure, a non-linear detection circuit based on welding thermal deformation includes a power supply module A1, a GPRS module A5, and a single-chip microcomputer module A4. It also has a voltage detection circuit 1, a current detection circuit 2, a light intensity detection circuit 3, a sound detection circuit 4, and a spacing detection circuit 5. The power supply module A1, GPRS module A5, single-chip microcomputer module A4, voltage detection circuit 1, current detection circuit 2, light intensity detection circuit 3, sound detection circuit 4, and spacing detection circuit 5 are installed on the circuit board inside the component box 6. The component box 6 is installed in the middle of the upper end of the front arm of the automatic welding robot 7. The spacing detection circuit is equipped with a ranging module A2, and the ranging module A2 is installed at the upper front end of the upper end of the front arm of the machine, and the detection head is aligned with the welding torch head 71 at the front end of the front arm of the machine.

[0017] Figure 1 , 2 As shown in the figure, the voltage detection circuit includes a rectifier bridge stack A, resistors R1 and R2, and a capacitor C1 connected by circuit board wiring. The positive power output terminal 3 of the rectifier bridge stack A is connected to the positive electrode of the capacitor C1 and one end of the first resistor R1. The other end of the first resistor R1 is connected to one end of the resistor R2. The other end of the second resistor R2 is connected to the negative electrode of the capacitor C1 and the negative power output terminal 4 of the rectifier bridge stack A. The current detection circuit includes resistors R11 and R12, a capacitor C2, a current transformer T, and a rectifier bridge stack A6 connected by circuit board wiring. The secondary power output terminal of the current transformer T is respectively connected to the two power input terminals 1 and 2 of the rectifier bridge stack A6. The positive power output terminal 3 of the rectifier bridge stack A6 is connected to the positive electrode of the capacitor C2 and one end of the first resistor R11. The other end of the first resistor R11 is connected to one end of the second resistor 1R2. The other end of the second resistor R12 is connected to the negative electrode of the capacitor C2 and the negative power output terminal 4 of the rectifier bridge stack A6. The phase wire of the total power input terminal of the automatic welding robot passes through the central hole of the current transformer T. The light intensity detection circuit includes a photoresistor RL and a resistor R3 connected by circuit board wiring. One end of the photoresistor RL is connected to one end of the resistor R3, and the light-receiving surface of the photoresistor RL is located outside the front-end opening of the component box 6. The sound detection circuit includes a voice control module A3, and resistors R9 and R10 connected by circuit board wiring. The power output terminal 3 of the voice control module A3 is connected to one end of the first resistor R9. The other end of the first resistor R9 is connected to one end of the second resistor R10. The other end of the second resistor R10 is connected to the negative power input terminal 2 of the voice control module A3. The spacing detection circuit includes two resistors R7 and R8 and is connected to the ranging module A2 by a wire. The signal output terminal 3 of the ranging module A2 is connected to one end of the first resistor R7. The other end of the first resistor R7 is connected to one end of the second resistor R8. The other end of the second resistor R8 is connected to the negative power input terminal 2 of the ranging module A2.

[0018] Figure 1 , 2As shown, the power input terminals 1 and 2 of the power module A1 are respectively connected to the two poles of the AC 220V power supply through wires. The power output terminals 3 and 4 of the power module A1 are respectively connected to the power input terminals 1 and 2 of the GPRS module A5, the power input terminals 1 and 2 of the single-chip microcomputer module A4, the power input terminals 1 and 2 of the rectifier bridge A of the voltage detection circuit, the other end of the resistor R12 at the power input terminal of the current detection circuit, the other end of the photosensitive resistor RL at the power input terminal of the light intensity detection circuit and the other end of the resistor R3, the power input terminals 1 and 2 of the sound control module A3 at the power input terminal of the sound detection circuit, and the power input terminals 1 and 2 of the ranging module A2 at the power input terminal of the distance detection circuit through wires. The signal input terminal of the GPRS module A5 and the signal output terminal of the single-chip microcomputer module A4 are connected through an RS485 data line. One end of the resistor R2 at the signal output terminal of the voltage detection circuit, one end of the resistor R12 at the signal output terminal of the current detection circuit, one end of the resistor R3 at the signal output terminal of the light intensity detection circuit, one end of the resistor R9 at the signal output terminal of the sound detection circuit, one end of the resistor R7 at the signal output terminal of the distance detection circuit, and the five signal input terminals 4, 7, 3, 6, and 5 of the single-chip microcomputer module are respectively connected through wires.

[0019] Figure 1 , 2As shown, after the AC 220V power supply enters the power input terminal of power module A1, the power output terminal of power module A1 outputs a stable DC 12V power supply to enter the power input terminals of the voltage detection circuit, current detection circuit, light intensity detection circuit, sound detection circuit, distance detection circuit, as well as the single-chip microcomputer module and the GPRS module, and the above circuits are powered on to work. After the voltage detection circuit is powered on and works, when the on-site power supply voltage is higher, the voltage signals output from pins 3 and 4 of bridge rectifier A are relatively high, and vice versa. This voltage signal is filtered by capacitor C1, and the voltage is reduced and the current is limited by resistors R1 and R2 and then enters pin 4 of single-chip microcomputer module A4. After the current detection circuit is powered on and works, when the total current input during the operation of the automatic welding robot is larger, the current flowing through current transformer T is larger, and the AC current and voltage signals output from the secondary side of current transformer T are higher, and vice versa, the output AC current and voltage signals are lower. This AC signal is rectified by bridge rectifier A6, filtered by capacitor C2, and the voltage is reduced and the current is limited by resistors R11 and R12 and then enters pin 7 of single-chip microcomputer module A4. After the light intensity detection circuit is powered on and works, when the light generated by welding is stronger, the resistance value of photoresistor RL is relatively smaller, and the voltage signal obtained by dividing the voltage with resistor R3 and entering pin 3 of single-chip microcomputer module A4 is relatively high. When the light generated by welding is weaker, the resistance value of photoresistor RL is relatively larger, and the voltage signal obtained by dividing the voltage with resistor R3 and entering pin 3 of single-chip microcomputer module A4 is relatively low. After the sound detection circuit is powered on, when the sound generated by welding is louder, the voltage signal output from pin 3 of the sound control module A3 at its signal output terminal is higher, and vice versa, the output voltage signal is lower. This voltage signal is divided by resistors R9 and R10 and then enters pin 6 of single-chip microcomputer module A4. After the distance detection circuit is powered on and works, when the distance between the welding torch head and the workpiece is relatively far, the voltage signal output from pin 3 of the ranging module A2 at its signal output terminal is higher, and vice versa, the output voltage signal is lower. This voltage signal is divided by resistors R7 and R8 and then enters pin 5 of single-chip microcomputer module A4. After the dynamic voltage, current, light intensity, sound, and distance signals reach the five signal input terminals of single-chip microcomputer module A4, single-chip microcomputer module A4 converts the above dynamic analog signals into digital signals and enters GPRS module A5. GPRS module A5 transmits the above data wirelessly, and the relevant Internet devices at the remote end (such as smart phones or PCs) receive and display the data on the screen. The relevant management personnel at the remote end can understand the relevant data in real time without being on-site (for example, based on the data displayed on the display screen and the experience data accumulated usually, it can be judged that the continuous current during welding is too large or too small for a long time, the voltage is too large or too small for a long time, no arc light is generated continuously during welding or the arc light is too large, no sound signal is generated continuously during welding or the sound signal is abnormal (too large or too small), and the distance between the front end of the welding torch head and the workpiece is too large or too small for a long time (short-term is not representative because it is normal for the corresponding data to be larger or smaller during the initial startup and short-term of the welding robot)). Figure 2As shown, the resistance values of resistors R1, R2, R3, R7, R8, R9, R10, R11, and R12 are 10K, 4.7K, 10K, 10K, 4.7K, 10K, 4.7K, 10K, and 4.7K respectively; the laser ranging module A2 is a finished product of the laser ranging module of model GJD-01, which has two power input terminals and one signal output terminal. When the distance between the transmitting head of the laser ranging module A2 and the obstacle (reflector) is closer, the voltage signal output by the signal output terminal is lower, and vice versa; the GPRS module A5 is a finished product of the GPRS module of model ZTWL-DTU; the main control chip model of the single-chip microcomputer module A4 is STC12C5A60S2. There are multiple analog signal input terminals and two power input terminals on the finished product of the single-chip microcomputer module A4, and there is an RS485 data output port on the finished product of the single-chip microcomputer module A4; the power supply module A1 is a finished product of an AC 220V to DC 12V switching power supply module; the capacitors C1 and C2 are of model 470μF / 25V; the photoresistor RL is of model MD45; the voice control module A3 is a sound detection module of model LM386, which has two power input terminals and one signal output terminal. The greater the detected sound signal, the higher the output voltage signal, and vice versa, the lower the output voltage signal; the current transformer T is a finished product of a small current transformer of model DL-CT08C; the rectifier bridge stacks A and A6 are of model KBP301.

[0020] The above shows and describes the basic principles, main features, and advantages of the present invention. For those skilled in the art, it is obvious that the present invention is limited to the details of the above exemplary embodiments, and without departing from the spirit or basic features of the present invention, the present invention can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended to embrace all changes that fall within the meaning and scope of the equivalent elements of the claims in the present invention. Any reference signs in the claims should not be regarded as limiting the claims involved.

[0021] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in the embodiments can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A welding thermal nonlinear detection circuit, including a GPRS module and a single-chip microcomputer module, characterized in that: It also has a voltage detection circuit, a current detection circuit, a light intensity detection circuit, a sound detection circuit, and a spacing detection circuit; the GPRS module, the single-chip computer module, the voltage detection circuit, the current detection circuit, the light intensity detection circuit, the sound detection circuit, and the spacing detection circuit are installed in a component box, the component box is installed in an electric control box of the automatic welding robot, the spacing detection circuit is equipped with a distance measuring module, the distance measuring module is installed at the upper end of the machine forearm of the automatic welding robot and its detection head is aligned with the welding gun head of the machine forearm; the signal input end of the GPRS module is electrically connected to the signal output end of the single-chip computer module, and the signal output ends of the voltage detection circuit, the current detection circuit, the light intensity detection circuit, the sound detection circuit, and the spacing detection circuit are electrically connected to the multi-channel signal input of the single-chip computer module.

2. The welding thermal nonlinear detection circuit according to claim 1 is characterized in that: The voltage detection circuit includes an electrically connected rectifier bridge stack, a resistor, and a capacitor. The positive power supply output end of the rectifier bridge stack is connected to the positive electrode of the capacitor and one end of the first resistor, the other end of the first resistor is connected to one end of the second resistor, and the other end of the second resistor is connected to the negative electrode of the capacitor and the negative power supply output end of the rectifier bridge stack.

3. The welding thermal nonlinear detection circuit according to claim 1 is characterized in that: The current detection circuit includes an electrically connected resistor, a capacitor, a current transformer, and a rectifier bridge stack. The secondary side power supply output end of the current transformer is respectively connected to the two ends of the rectifier bridge stack power supply input. The positive power supply output end of the rectifier bridge stack is connected to the positive pole of the capacitor and one end of the first resistor. The other end of the first resistor is connected to one end of the second resistor. The other end of the second resistor is connected to the negative pole of the capacitor and the negative power supply output end of the rectifier bridge stack. The phase line of the total power supply input end of the automatic welding robot passes through the center hole of the current transformer.

4. The welding thermal nonlinear detection circuit according to claim 1 is characterized in that: The light intensity detection circuit comprises a photoresistor and a resistor which are electrically connected, one end of the photoresistor is connected to one end of the resistor, and the light receiving surface of the photoresistor is located outside the front end of the component box.

5. The welding thermal nonlinear detection circuit according to claim 1 is characterized in that: The sound detection circuit includes an electrically connected sound control module and a resistor, wherein the power output end of the sound control module is connected to one end of the first resistor, the other end of the first resistor is connected to one end of the second resistor, and the other end of the second resistor is connected to the negative power input end of the sound control module.

6. The welding thermal nonlinear detection circuit according to claim 1 is characterized in that: The distance detection circuit includes two resistors and is electrically connected to the ranging module. The signal output end of the ranging module is connected to one end of the first resistor, the other end of the first resistor is connected to one end of the second resistor, and the other end of the second resistor is connected to the negative power input end of the ranging module.

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